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CTN10-16
Screw compressor
Version 1.00
F019684-
2. Safety ...................................................................................................................................... 2
2.1 Safety during installation and preparations for use ...................................................... 2
2.2 Safety during operation ................................................................................................ 3
2.3 Safety during maintenance........................................................................................... 3
2.4 Safety signs.................................................................................................................. 4
8. Troubleshooting .................................................................................................................. 27
(Directive 2006/42/EC)
Tampere 1.10.2013
(Place) (Date)
(Signature)
Gardner Denver Oy
P.O.Box 516
FIN-33101 Tampere
Finland
1. Introduction
1. Introduction
Gardner Denver wishes you welcome among the users of Gardner Denver screw compressors!
This manual gives you instructions on correct and safe operation and maintenance of your screw
compressor.
Read these and other instructions with the compressor carefully before using your screw
compressor. This ensures correct preparations and use from the very beginning.
All the instructions in this manual have been provided to guarantee a long life and reliable operation of your
screw compressor.
Always keep the manual available near the compressor. Make sure that the compressor is operated and
serviced according to the instructions.
Get acquainted with the Gardner Denver warranty terms, which are enclosed with the manuals for the
compressor. Fill in the warranty registration card with care and return it to the seller as instructed.
The warranty becomes void if the terms are not observed or if other than original Gardner Denver spare
parts are used. Use only the recommended AEON oil types in order to ensure undisturbed operation.
All the service and maintenance duties, which are not covered in this manual should be made only by
trained and qualified service personnel authorized by Gardner Denver or its representative.
There is a log book enclosed with the manuals for the compressor. Always fill it in after any maintenance or
repair work.
1.4 Inquiries
When making inquiries concerning your screw compressor, always quote the complete type specification
and the serial number as they are given on the data plate of the compressor.
Gardner Denver reserves the right to change the construction and manuals of the compressors without
prior notice.
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2. Safety
2. Safety
The general safety instructions concerning the compressor are presented in this chapter.
Read also the safety instructions for transportation, installation, operation and maintenance
presented separately in each section of the manual.
In addition to these instructions, the local regulations in your country may impose additional requirements
that must be observed.
The noise level of the compressor, which is presented in the "Technical data" on page 30, is determined
according to ISO2151 and ISO3744. The noise level may rise higher if the walls surrounding the installing
location reflect sound. Take this into consideration, when choosing the best location for the compressor.
The intake air for the compressor must be clean and cool. Prevent the used and hot cooling air
circulating back to the cooling air intake. Make sure that foreign objects cannot get into the compressor
with the intake air. The intake air must not contain any explosive or inflammable gases or harmful
substances.
Do not exceed compressor's rated maximum pressure, capacity or rotation speed. For more details see
"Technical data" on page 30.
Use pneumatic hoses that can hold the working pressure. Pay special attention to the hose mountings.
The pressure in the hoses must be removed before disconnecting. A whipping hose may cause
unpredictable damage.
The pressure vessels in the pressurized air network must be in accordance with the pressure vessel
regulations.
Only authorized and qualified personnel should make the electrical connections.
The condensate water contains oil. It should be disposed of according to the local regulations on waste oil.
2
2. Safety
Use only the recommended AEON oil types. Do not mix different types of oil.
While doing maintenance, the compressor must always be stopped and disconnected from the electrical
mains connection. The shut-off valve of the pressurized air network must also be closed. Make sure that
there is no pressure in the air/oil receiver before starting maintenance.
All alterations must comply with the pressure vessel regulations PED 97/23/EC.
Do the regular checkups and maintenance of the compressor in order to ensure undisturbed operation.
Maintenance and service operations other than described in this manual must be left to service personnel
authorized by Gardner Denver.
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2. Safety
Read User Manual before starting the compressor Wear ear protectors
General meaning of geometric shapes, safety colors and contrast colors for the safety signs
Graphical symbol
Geometric shape Meaning Safety color Contrast color
color
4
3. Main components
3. Main components
The screw compressor is an oil-cooled single stage screw compressor. The pressurized air is produced
with a screw air end driven by an electric motor. Oil is separated from the compressed air in an oil
separation receiver. Oil is cooled before injecting into the air end.
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3 8
4
9 5 7 2
5
3. Main components
8 10
3
4
1
9 5 2 7
6
4. Handling instructions
4. Handling instructions
If the compressor is stored for a long period of time, the stockroom must be dry and warm. Check the
functioning of the belt tightening before starting the compressor first time after the storing.
If the compressor is stored unused for over 12 months, please contact an authorised Gardner Denver
retailer before using the equipment again.
Lifting and transporting the compressor requires caution. Check the compressor’s centre of gravity from
Dimensional drawings.
The water separator (if available) must be removed before lifting the compressor.
Lifting points
Lifting points
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4. Handling instructions
Insert the forks under the compressor in the directions shown in the following figure.
4.3 Decommissioning
When the compressor is decommissioned, the compressor oil, the oil filter and the oil separator elements
must be disposed of in accordance with local hazardous waste regulations.
Decommissioning
The WEEE label means the product must be disposed of separately from other waste.
Appropriate recycling of the product helps to maintain a cleaner environment. For
more information about recycling the product, please contact your local authorised
Gardner Denver retailer.
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5. Operating instructions
5. Operating instructions
1. Check for sufficient oil level in the receiver. For more information, see "Adding and changing
oil" on page 16 and "Oil recommendations" on page 25.
3. Make sure the screw elements rotate in the correct direction before starting the compressor .
Correct rotation direction must always be ensured after the power supply or motor cables have been
disconnected and reconnected.
Do not control the air flow in the compressed air network using the shutter valve. Misuse of the shutter valve
may cause a rapid deflation of the system and increases oil consumption.
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6. Operating principles
6. Operating principles
1. Housing
2. Female rotor
3. Male rotor
4. Discharge flange
5. Shaft seal
6. Bearing cover
Screw unit
Rotors
In a screw compressor the air is compressed in the air end driven by a motor.
The meshing rotors take air in between the ridges as they pass the inlet opening. When the rotors turn, the
connection to the inlet opening closes and the space between the ridges starts to decrease. At the end of
the compression phase, the desired pressure has been reached and the connection to the receiver opens.
The air in the air end is cooled by oil that is injected into it. The oil cools also the air end. In addition, the oil
lubricates the bearings and seals the clearances between the rotors and the rotor housing.
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6. Operating principles
From the compressor air end the mixture of pressurized air and oil mist is ducted into the oil separating
receiver, where oil is separated from the pressurized air. The separating process has two phases.
Main part of the oil is separated in the cyclone (10) in the receiver, where the centrifugal effect is utilized.
The separated oil flows to the bottom of the receiver (11). The remainder of the oil is separated from the air
by means of oil separator (1). The oil separated in the oil separator is led back into circulation through the
oil return pipe (2). The return pipe is provided with an orifice plate (3) that prevents excess air recirculation
back into the compressor air end.
The internal pressure forces the oil back to the circulation through the oil cooler (8) and the oil filter (4).The
oil circulation is controlled by an oil thermostat valve (5). The oil thermostat valve controls the oil flow to the
oil cooler and to the oil cooler by-pass.
The forced oil circulation is maintained by the pressure difference between the receiver and the
compressor air end. To quarantee oil circulation whenever the compressor produces pressurized air, the
discharge valve (6) prevents the receiver pressure from dropping below the set minimum level (5 bar).
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6. Operating principles
The compressed air is led out through the discharge valve (6). Alternatively (option) the compressed air is
led from the discharge valve to the after-cooler (7), where it´s temperature drops.
The pressure relief valve (9) protects the receiver against overpressure. It opens at a certain pressure,
preventing the receiver pressure from rising dangerously high.
The control system adjusts compressor output in accordance with the current air consumption and
maintains uniform pressure. It also cuts the power consumption for each cubic meter of pressurized air as
low as possible.
The output control range is continuous, and ranges from zero to full output capacity. Output is adjusted by
opening and closing the intake valve. The intake valve is controlled automatically by a control valve that
measures compressor pressure and regulates it so that it remains within a set fluctuation range (normally 1
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6. Operating principles
bar). The fluctuation range limits the allowed output pressure, which may fluctuate because of changing air
consumption.
When the motor is stopped, the blow-down valve depressurises the receiver.
Output pressure can be regulated by turning the adjusting screw (B) on the control valve.
Locking nut (A) must be loosened before adjusting: turning the screw (B) clockwise increases pressure
and turning it counterclockwise lowers the pressure.
Capacity control
Compressor must never be used without temperature sensor. Misuse may cause
serious damage !
At 100°C the temperature alarm lights and at 115°C the compressor will stop.
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7. Maintenance instructions
7. Maintenance instructions
Maintenance and service operations other than those described in this manual must be left to service
personnel authorized by Gardner Denver.
Use only original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.
Before any maintenance operations, switch off the compressor with the main switch and make sure that the
compressor cannot be accidentally started.
1. Stop the compressor and make sure that there is no pressure in the receiver. Wait for 2
minutes after stopping for the blow-down function to empty the receiver.
2. Turn the power off at the main switch and make sure that the compressor cannot be
accidentally started.
3. Close the shut-off valve between the compressed air network and the compressor.
The space between the discharge valve and the system shut-off valve stays under pressure when the
compressor is stopped and the shut-off valve is closed. Release the pressure before starting maintenance.
2. Open the shut-off valve between the compressed air network and the compressor.
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7. Maintenance instructions
In the case of extreme operating conditions, it is advisable to halve the service intervals. The compressor’s
rapid cycling between unloading and loading will shorten the service intervals. Please contact an authorized
distributor of Gardner Denver for more information.
The maintenance intervals below are recommended for portable equipment and correspond approximately to
the maintenance interval of the motor and other components.
Service chart
Action 1 2 3 4 5 6 7 8 9
1) Daily 6) As required
2) After the first 50h 7) Every 3 years / 5000h
3) Every 500h 8) Every 5 years / 10 000h
4) Every 1000h 9) Every 10 years / 20 000h
5) Once a year
* Stop the compressor before checking the oil level. Wait until the oil is separated from the air, about 10 min.
** Thermometer´s functionality is tested by using a heater (operation range 0-120 °C) to heat the sensor to the temperature
limits. Do not use fire.
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7. Maintenance instructions
Do not open the oil filling plug or cooler drain plug if the system is pressurized.
2. Open the oil filling plug (1) and add new oil until the oil-checking glass is filled. Note! Do not
over fill.
4. Close the pressure relief valve (2) and open the network shut-off valve.
Adding oil
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7. Maintenance instructions
2. See "Before maintenance" on page 14 for precautions before starting the work.
3. Open the oil filling plug (1) and the oil drain plug (3). Drain oil into a suitable receiver. Close the
oil drain plug (3).
Changing oil
4. Replace the oil filter, see "Replacing the oil filter" on page 17.
5. Add new oil and close the oil filling plug (1).
6. Close the pressure relief valve (2) and open the network shut-off valve.
7. (Start the compressor and let it run for 5 minutes. Stop the compressor and wait for a while so
that oil settles and the pressure drops. Add new oil again. Repeat this two times.
Allow the compressor to cool down before replacing the oil filter.
Dispose the used oil filter in accordance with local hazardous waste regulations.
Only use original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.
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7. Maintenance instructions
2. The oil filter is installed on the air end. Use a protective cloth, as some oil will drain out when
the filter is removed.
Oil filter
Remove the filter with caution. Make sure that particles do not get into the inlet air channel.
Use only original Gardner Denver spare parts. The use of other spare parts may compressor damage.
2. Remove the air filter cover (3) and the old filters(2).
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7. Maintenance instructions
4. Install the new air filters (2) and its cover (3) back to their places.
1 2 3 4
Dispose the used oil separation cartridge in accordance with local hazardous waste regulations.
Use only original Gardner Denver spare parts. The use of other spare parts may cause compressor damage.
1. See "Before maintenance" on page 14 for precautions before starting to replace the oil
separator cartridge.
5. Replace the filter strainer (4) and clean the oil separator housing.
6. Lubricate the O-ring (5) of the separator cartridge and install new separator cartridge (2) by
hand.
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7. Maintenance instructions
Visually check the compressor for oil leaks, in particular around the compressor unit, the oil cooler and the
oil hoses.
Check all hoses for cracks, blisters, tears, leaks, and stiffness. Replace as required
Always use original pneumatic hoses that are rated to withstand the working pressure and temperature. Pay
particular attention to the hose installings as a lose hose can flail and cause unpredictable damage.
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7. Maintenance instructions
A clogged cooler increases the output air temperature and may lead to a compressor stoppage.
Clean the cooler with pressurized air, see the picture. For a more effective cleaning, brush the cooler from
underneath. Note! Do not use a metal wire brush.
If the cooler is very dirty, remove it from the compressor and clean the outside with mild detergent.
For more information on cleaning the cooler, please contact an authorized distributor of Gardner Denver.
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7. Maintenance instructions
A ( 0,24 : 1 )
Screw
2. Untighten the screw counterclockwise until the belts are loose enough. (The screw pushes the
motor up so that belts loosen.)
Remove the two screws and insert one into the removal hole. Tighten the screw evenly until the sleeve
comes off the hub. Remove the loose pulley manually from the shaft, taking care not to damage the shaft
(do not hammer). Sleeve comes off with the pulley.
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7. Maintenance instructions
1. Remove protective grease from the sleeve and the pulley hub. Fix the sleeve to the pulley and
align the holes.
2. Grease the two fixing screws (1), insert them into the holes shown in the figure, and tighten
lightly. Threads are in the pulley.
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7. Maintenance instructions
3. Clean the shaft, and install the pulley with the sleeve on it. Note that the sleeve fastens first,
after which the pulley can still be moved a bit in relation to the sleeve. Bear this in mind when
aligning the pulleys.
5. Knock the sleeve lightly with a drift, and retighten the screws. Repeat this a few times to
make sure the sleeve is firmly fixed in place.
7. Fill the extraction holes e.g. with grease to protect them against dirt.
Sleeve Tightening
torque (Nm)
1610 20
2012 31
2517 49
NOTE! Sleeve type is marked on the end of the sleeve
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7. Maintenance instructions
All adjustment and repair operations of the pressure relief valve must be performed by qualified
maintenance technicians. All local regulations must be observed.
The compressor must be stopped and secured from automatic restart before attempting this procedure.
The opening pressure of the pressure relief valve must be tested in a separate pressurized air line. The
pressure relief valve has been tested at the manufacturer's site before shipping out the compressor. If the
valve has been replaced, it needs to be tested for proper operation. This procedure can be performed only
by a qualified mechanican.
The operation of the valve can be tested by turning the cap (1) counter-clockwise 1 to 2 turns. Always
tighten up the pressure relief valve cap properly to avoid damage caused by vibration.
These oil recommendations are for Gardner Denver screw compressors in industrial use.
Gardner Denver compressors are factory filled with AEON lubricants. These lubricants are formulated to
the highest quality standards and are factory authorized, tested and approved for use in screw
compressors. AEON lubricants are available through your authorized Gardner Denver compressor
distributor.
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7. Maintenance instructions
Package size AEON 3000* order no. AEON 9000 SP order no.
7.14.3 General guidelines for oil change intervals for mobile use
For recommended oil change intervals, please see the table below.
Operating temperature of the compressor can be seen in temperature gauge. (Not supplied).
Specific AEON lubricants are recommended for use in this equipment. Other lubricants will cause:
• shortened life time of oil filter, oil separating cartridges and oil
• varnishing and blockage of oil circuit
• increased oil consumption
• excessive oil carryover and compressor damage
Note! If wrong oil type has been used or oil circuit is varnished, please contact an authorized distributor of Gardner
Denver for oil circuit cleaning instructions.
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8. Troubleshooting
8. Troubleshooting
Troubleshooting table
27
8. Troubleshooting
Troubleshooting table
Pressure relief valve open • Close the cap of the valve by hand
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8. Troubleshooting
Troubleshooting table
COMPRESSOR STARTS Supply voltage too low • Check the supply voltage
TOO SLOWLY
• See "Oil recommendations" on page
Wrong oil type
25.
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9. Technical Appendixes
9. Technical Appendixes
Technical data
Dimensional drawings
30